Johnson & Starley WARMCAIR C10DW Installation guide

Brand: Johnson & Starley

Model: WARMCAIR C10DW

Category: Water heaters & boilers

Type: Installation guide

www.johnsonandstarley.co.uk

Johnson & Starley Ltd

Rhosili Road

Brackmills, Northampton

NN4 7LZ

WarmCair Condensing Warm Air

and Hot Water

FM 525200

For Installation in Mainland UK only.

INSTALLATION,

COMMISSIONING

& SERVICING

INSTRUCTIONS

WARMCAIR C10DW

Condensing Air & Water Heater

High Efﬁciency Downﬂow

Condensing Air & Water Heater

WarmCair C10DW - G.C. No. 43-417-59

These instructions are to be left with the User

Publication No. ZZ 1446-5

October 2021

www.johnsonandstarley.co.uk

TECHNICAL UPDATES

INFORMATION REGARDING UPDATES TO THIS MANUAL ARE LISTED BELOW AND SHOULD BE NOTED BEFORE

COMMENCING WITH ANY INSTALLATION WORK.

Date of Amendment Version No Page Description

15/05/2020 ZZ1446-4 5 Amendment to Magnetic-Non Magnetic Filter requirements

15/05/2020 ZZ1446-4 15 Changes to parts and part Numbers

15/05/2020 ZZ1446-4 29 New Fault Finding Flow Charts

15/05/2020 ZZ1446-4 39 Changes to list of ancillaries

31/03/2021 ZZ1446-4 8 Amendment to Return Air duct system

Sales/Spares & Replacement Help Line 01604 762881

CONTENTS

The Benchmark Scheme 3

1. Features 4

2. General Description 4

3. Building Standards & Regulations 5

4. Safety, Electrical & Gas Information 5

General Safety Information

Power Flushing

Electrical Connections

Handling the unit

Operating the Appliance

Gas Supply

Water Supply

5. Technical Data 7

Technical Data

Performance Data

6. Heater Positioning 8

7. Heater Compartment Clearances 8

8. Duct System 8

Return Air

9. Heating System 9

Warm Delivered Air System

Additional Radiator System If Fitted

Schematics

Pipework Sizing

Water Treatment

Hot Water System For DHW

10. Flue Instructions 11

Types of Flue Systems

Flue Terminal Positions

Flue Requirements & General Information

Extended Horizontal Flue Conﬁguration Example

Vertical Flue Conﬁguration Example

Optional Roof Outlets

Plume Terminal Outlets

Conventional 60/100 mm Flue Accessories Part No.s

11. Condensate Pump & Drain Tube 16

Condensate Pump

Condensate Tube Routing Options

12. Electrical 17

13. Warm Air Fan Performance 17

14. Operating Modes 17

15. Domestic Hot Water Heating Commissioning 18

Check Gas Installation

Check the Operational Gas Inlet Pressure

Air Purge Function

Reset Procedure

16. Initial Lighting 19

Warm Air Central Heating

Water Circulation System

Balance the System

Central Heating Water Temperatures

17. Warm Air Heating Commissioning 20

With No OpenTherm Controller Fitted

18. Handing Over 19

19. Servicing & Maintenance 21

Service Schedule

Initial Inspection

Servicing Sequence

Flue Inspection & Checks

Gaining Access to the Hot Water

Air Filter Removal

Upper Panel Removal

Control Panel

Combustion Air Fan

Burner Assembly

Water Heat Exchanger

Gaining Access for Servicing the Heat Generator

Lower Panel Removal

Air Circulation Fan

Air Heat Exchanger

Condensate Pump

Condensate Trap

20. Parts Replacements 25

Part Replacements without Draining the System

Control Panel

Burner Injector

Combustion Air Fan

Burner Assembly

Flow & Return Thermistor Sensors

Ignition/Detection Electrode

Gas Valve

Warm Air PCB

PCB Interface

Air Circulation Fan

Condensate Pump

Condensate Trap

Diverter Actuator Head

Parts Replacement By Draining the System

Draining the Appliance

Pump Head

Diverter Cartridge

Automatic Air Vent

Air Heat Exchanger

21. Fault Finding 29

22. Wiring Diagram 37

23. Dimensions 38

24. Exploded Spares Diagram 39

25. List of Spares 40

26. List of Ancillaries 42

27. Benchmark Checklist and Service Record 43

Code of Practice

Commissioning Checklist

Service Record

In the interest of continuous development Johnson and Starley reserves the right to change speciﬁcation without prior notice. Johnson

and Starley prides itself on its ability to supply spare parts quickly and efﬁciently.

PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.

LEAVE THESE INSTRUCTION WITH THE USER OR AT THE GAS METER AFTER INSTALLATION

The Benchmark Scheme The Benchmark Scheme

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are

provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with

the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building

Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be

provided to the customer for future reference.provided to the customer for future reference.

Visit www.centralheating.co.uk for more information.Visit www.centralheating.co.uk for more information.

Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice, which is available from the Heating and Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice, which is available from the Heating and

Hot water Industry Council who manage and promote the Scheme. Hot water Industry Council who manage and promote the Scheme.

www.johnsonandstarley.co.uk

1. FEATURES

Appliance Classiﬁcation:

The WarmCair C10DW has been

tested and CE certiﬁed by BSI Ltd for

use with NATURAL gas G20.

FEATURES

1. Flue Adaptor

(shown ﬁtted but not supplied)

2. Flue Test Point

3. Inspection Glass

4. Ignition Detection Electrode

5. Burner Injector

6. Flow & Return Sensors

7. Pressure Differential Tube

8. Gas Valve

9. Air Filter

10. Condensate Trap

(at the back)

11. Gas Cock

12. Circulation Fan

13. HE Pump/Diverter Assembly

14. Return Water Temperature Sensor

15. Heat Exchanger

(warm Air)

16. Drain Cock

17. Access Panel

18. Condensate Pump

19. Condensate Pipe

20. Condensate Drain Tube

21. Electronic Air Filter & LED

22 PCB Interface

23. Combustion Fan

24. Warm Air PCB

25. Heat Generator

(water)

26. Flue Sensor

2. GENERAL DESCRIPTION

2.1 The WarmCair C10DW is a highly efﬁcient combined condensing gas-ﬁred water-to-air downﬂow forced

convection air heater and water heater. Signiﬁcant reductions in Carbon and NOx emissions are achieved.

This appliance has been designed with two compartments, one to provide the user with Warm Air Central

Heating and one to provide Domestic Hot Water. Using sophisticated controls, enabling it to provide a warm

air heat output of 16.0 kW and hot water output of 24.2 kW, fully modulating down to 4.8 kW. It is room

sealed, with a stainless steel heat exchanger, using a vertical or horizontal Concentric Flue System.

The WarmCair C10DW combines air heater is ideally suited for new built dwellings and the replacement of

existing non-condensing air heaters. For Indirect system applications only.

2.2 “Summer Air Circulation” of unheated air is available by manual selection (see the user’s instructions)

2.3 The air is drawn in through the air ﬁlter or air cleaner (if ﬁtted) and the heat exchanger by a centrifugal fan, and

discharged through the base of the unit. A Summer Air Circulation switch (optional) provides the facility to supply

unheated air to the air outlets during warm weather. Modairﬂow control is incorporated for modulating of the air

circulation fan.

FIGURE 1. CONTROL PANEL

Sales/Spares & Replacement Help Line 01604 762881

3. BUILDING STANDARDS & REGULATIONS

STATUTE LAW DEFINES THAT ALL GAS APPLIANCES MUST BE INSTALLED BY

COMPETENT PERSONS, i.e. GAS SAFE REGISTERED INSTALLERS.

GAS SAFE MEMBERSHIP ENQUIRIES TEL: 0800 408 5500 IN ACCORDANCE WITH

THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION).

FAILURE TO COMPLY WITH THESE REGULATIONS MAY LEAD TO PROSECUTION.

3.1 INSTALLATION REGULATIONS

• Building Standards (Scotland) (Consolidation) Regulations

• Building Regulations Part L

• Gas Safety (Installation and Use) Regulations (as amended)

• The Water Fittings Regulations or Water bylaws in Scotland

• Model and Local Authority Byelaws

• Health & Safety Document No. 635.

• The Electricity at Work Regulations, 1989.

• Institute of Electrical Engineers (I.E.E) Wiring Regulations

• EU Regulation No 811/2013 and No. 812/2013 supplement Directive 2013/20/EU

This appliance has been Tested and Certiﬁed in order to meet the necessary European Directives

and comply with the latest Building Regulations.

• Efﬁciency of Hot Water Boilers Directive 92/42/EEC

• Gas Appliance Directive 2009/142/EC

• Low Voltage Directive 2006/95/EEC

• Electromagnetic Compatibility Directive 2004/108EC

3.2 BUILDING STANDARDS AND REGULATIONS

Where no speciﬁc instructions are given, reference should be made to the relevant British Standard Code of

Practice.

BS 5440:1 Flues (for gas appliances of rated input not exceeding 70 kW).

BS 5440:2 Ventilation (for gas appliances of rated input not exceeding 70 kW).

BS EN 12828 Heating Systems in buildings: Design for water based heating systems.

BS EN 12831 Heating Systems in buildings: Method for calculation of the design heat load.

BS EN 14336 Heating Systems in buildings: Installation and commissioning of water based

heating systems.

BS 5546 Installation of gas hot water supplies for domestic purposes (2nd Family Gases)

BS 6798 Installation of gas ﬁred hot water boilers of rated input not exceeding 70 kW.

BS 6891 Installation of Low Pressure Gas Pipework of up to 28mm (R1) in domestic

premises (2nd family gases).

BS 7671 Institute of Electrical Engineers (I.E.E) Wiring Regulations

IMPORTANT: This appliance is UKCA certiﬁcated for safety and performance. It is important that no modiﬁcations are

made to this appliance, unless fully approved in writing by Johnson & Starley Ltd. If in doubt, please ring Johnson & Starley

Ltd on Telephone 01604 762881.

4. SAFETY, ELECTRICAL, GAS & WATER INFORMATION

PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE COMMENCING WITH THE INSTALLATION

4.1 GENERAL SAFETY INFORMATION

4.1.1 Only use WarmCair original spare parts on this appliance. Failure to do so will invalidate the guarantee.

4.1.2 The manufacturer’s instructions supplied must not be taken as overriding any statutory requirements.

4.1.3 No artiﬁcially softened water should be used to ﬁll the central heating system.

4.2 POWER FLUSHING - When a radiator system is also connected.

4.2.1 The system can be damaged by debris entering the heat exchanger and reduce efﬁciency. It is recommended

that the appliance is ﬂushed, follow these guidelines as this will protect the unit and prolong its life.

4.2.2

It is important that the system is ﬂushed thoroughly before the appliance is left to operate (as recommended in BS

7593) in order to maintain an efﬁciently operating heating system. For replacement installations, the system MUST

be ﬂushed with the old unit in situ, in order to prevent the appliance becoming a trap for system debris. Once the

system has been ﬂushed, an inhibitor (suitable for stainless steel heat exchangers) should be added. Appropriate

inhibitors are available, for example Sentinel, Fernox and Salamader.

4.3 MAGNETIC AND NON MAGNETIC FILTERS

For new and replacement installations a Magnetic & Non Magnetic ﬁltration system must be ﬁtted on all returns to

the appliance.

4.3.1 Failure to carry out the above procedures will invalidate the guarantee!

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GAS LEAKS

DO NOT OPERATE ANY ELECTRICAL SWITCHES, OR USE A

NAKED FLAME TURN OFF THE GAS SUPPLY. VENTILATE THE

AREA BY OPENING DOORS AND WINDOWS. CALL THE NATIONAL

GAS EMERGENCY SERVICE ON

0800 111999

FIGURE 2. GAS COCK PRESSURE DROP

2.5

1.5

0.5

PRESSURE DROP (mbar)

0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0

HEAT INPUT TO BOILER (kW)

4.4 ELECTRICAL INFORMATION

4.4.1 Ensure the mains supply voltage, frequency, number of phases and power rating comply with details on the rating label.

4.4.2 All wiring must be in accordance with the appropriate standards. The equipment must be supplied with a double pole isolator

switch.

4.5 HANDLING THE UNIT

4.5.1 Ensure safety regulations and practices are adhered to when installing and using this equipment

4.5.2 The weight of this appliance exceeds that recommended for a one-man lift. It will therefore be necessary to gain assistance at

times during the installation procedure.

4.5.3 It should be noted that this appliance may contain sharp edges. Care MUST be taken when handling the appliance to prevent

injury.

4.5.4 Once the appliance has been ﬁred beware that certain parts will be hot to the touch.

4.5.5 Do not install ﬂues during rain, high winds or in severe weather conditions.

4.6 GAS SUPPLY

4.6.1 It is the responsibility of the Gas Installer to size the gas installation pipework in accordance with BS 6891. Whilst the principle of

the 1:1 gas valve ensures the WarmCair Combined DHW range is able to deliver its full output at inlet pressures as low as 14mb,

other gas appliances in the property may not be as tolerant. When operating pressures are found to be below the minimum

meter outlet of 19mb these should be checked to ensure this is adequate for correct and safe operation.

4.6.2 Allowing for the acceptable pressure loss of 1mb across the installation pipework, it can be assumed that a minimum permitted

operating pressure of 18mb will be delivered to the inlet of the appliance. (Reference BS 6400-1 Clause 6.2 Pressure Absorption).

4.6.3 The external gas cock could further reduce the operating pressure when measured at its test point. The pressure drop is relative

to the heat input to the boiler (kW), refer to graph below.

IMPORTANT: Installation pipes must be ﬁtted in accordance with BS 6891. In Ireland refer to IS.813.

4.7 WATER SUPPLY

4.7.1 Water connections to the unit should be by 22mm compression ﬁttings that are suitable for the duty.

NOTE: UNDER NO CIRCUMSTANCES SHOULD ISOLATION VALVES BE FITTED.

IMPORTANT: It is recommended that the water system be drained and ﬂushed prior to the installation of the unit. A strainer

should be ﬁtted upstream of the unit. See Paragraph 4.2.

Sales/Spares & Replacement Help Line 01604 762881

NOTE: Gas consumption is calculated using a caloriﬁc value of 38.7 MJ/m³ gross or 34.9 MJ/m³ nett. To

obtain the gas consumption at a different caloriﬁc value:

a. For l/s - divide the gross heat input (kW) by the gross C.V. of the gas (MJ/m³)

b. For ft³/h - divide the gross heat input (Btu/h) by the gross C.V. of the gas (Btu/ft³)

c. For m³/h - multiply l/s by 3.6

TABLE 2. C10DW

PERFORMANCE DATA

MAXIMUM MINIMUM

Burner CO² (%)

case off

9.3 8.4

case on

9.5 8.6

± 0.5

PERFORMANCE DATA FOR WATER HEATING

Input Q

Net

kW 17 4.40

Gross

kW 18.9 4.88

Gas Consumption

m³/h 1.75 0.45

Output

Non condensing kW 16.75

Condensing

kW 18.48 4.83

NOx Classiﬁcation

CLASS 5

Recommended Central Heating set point

80 °C

5. TECHNICAL DATA

TABLE 1. C10DW

Maximum weight lift kg 66

Gas supply mbar 2H - G20 - 20 mbar

Gas connection mm 15 mm copper

Gas Injector size mm 4.2 mm

Heating ﬂow and return mm 22 mm copper

Flue terminal diameter mm 100 mm (4”)

Condense drain mm 6 mm ID

Electrical supply V ~ Hz 230 V ~ 50 Hz

Electrical rating W 150

External fuse rating A 3

WARM AIR HEATING

Nominal Rated Output kW 10

Air on Temperature ˚C 20

Air off Temperature ˚C 67

Water Supply Temperature ˚C 80

Water Return Temperature ˚C 73

Water Flow Rate l/s 0.4

Air Volume m³/h 576

ADDITIONAL DATA

ELECTRIC POWER CONSUMPTION 100 W (at rated heating capacity), 30 W (at minimal cap.), 10 W (standby mode)

USEFUL EFFICIENCY 88.6 % (at rated heating capacity), 98.9 % (at minimum capacity)

ENVELOPE LOSS FACTOR 0

IGNITION BURNER POWER CONSUM. 0 W

EMISSIONS OF NITROGEN OXIDES 33 mg / kWh

EMISSION EFFICIENCY 84.71 %

SEASONAL SPACE HEATING ENERGY EFFIC. 81.6 %

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6. HEATER POSITIONING

6.1 This heater is not suitable for external installation unless it is protected from the elements by a suitable

enclosure. The enclosure must provide the clearance for installation, servicing and maintenance as well as

the correct level of ventilation. The selected position should allow for a suitable ﬂue system to be installed.

6.2 When installed in a timber frame, building guidance should be taken from the Gas Industry Publication IGE/

UP-7 (Guide for Gas Installations in Timber Frame Housing).

6.3 BS 6798 gives details of the essential features for a compartment or cupboard where a gas appliance is to

be installed. An existing cupboard may require modiﬁcation.

IMPORTANT: This system can only be used in conjunction with an indirect system application.

6.4 If the heater is installed in a room containing a bath or shower, it is important to locate the electrical switch

in a position where it cannot be touched by anyone using the bath or shower. The current IEE Wiring

Regulations (BS 7671) for England and electrical provision of the Building Regulations for Scotland gives

details.

6.5 Room ventilation for the heater is not necessary (as the heater draws its combustion air from the outside of

the building, cupboard or compartment ventilation), providing that the minimum clearances are maintained.

However, reference should be made to BS 5440 Pt. 2.

IMPORTANT: This appliance must be completely level. It MUST NOT lean in any direction. This would

cause problems with the condense draining.

7. HEATER COMPARTMENT CLEARANCES

7.1 IMPORTANT: If the heater is to be ﬁtted to an existing base duct (warm air plenum), always ensure that

installation is carried out such that the rear of the heater is aligned with the rear of the base duct so that any

overhang or blanking off will be at the front. In any event, blanking plates must be mechanically secured and

all joints sealed.

7.2 When the heater is ﬁtted into a compartment, a minimum clearance from the compartment walls of 3 mm

(1/8”) at the sides, rear and front must be left. Where clearances are less than 75 mm, internal surface must

be lined with non-combustible material and the compartment must be of a ﬁxed rigid structure. However,

there is no requirement for the use of non-combustible material at the front of the unit. Consideration should

also be given to the space required for the removal and replacement of the ﬁlter tray and the entry of the

gas and electrical supplies. If gas connections are made from a side entry, a minimum clearance of 75 mm

(3”) is required at that side.

7.3 For service access, a minimum clearance of 450 mm (18”) is required at the front of the heater. Space must

also be allowed, in a compartment installation, to permit the complete removal of the heater.

7.4 In airing cupboard installations, the part used as the air heater compartment must comply with the relevant

section of BS 5864 and must be completely separated by either a non-combustible partition or a perforated

metal partition with the perforations not exceeding 13 mm (½”). The secondary ﬂue must be a tight ﬁt where

it passes through the partition and must be suitably protected (see BS 5440: Part 1).

7.5 In understairs installations, the compartment must comply with the relevant section of BS 5864, provided

that in addition all internal surfaces (including the base) are non-combustible or lined with non-combustible

material. This requirement is applicable only to dwellings of more than two storeys.

7.6 In free-standing installations, (see instructions packed with top closure kit), only one or two walls will be in

close proximity to the air heater; these must be non-combustible.

7.7 Where the air heater is to be installed onto a combustible surface and under-ﬂoor ducting used, a suitable

base tray MUST be used in order to provide insulation.

NOTE: where a base plenum is used, no base tray is required!

7.8 Although two permanent ventilation openings are not required, consideration should be given to the amount

of heat emitted by any ductwork present in the compartment, otherwise the compartment temperature

could increase and will affect the safe operation of the appliance and its controls.

8. DUCT SYSTEM (See British Design Manual - Gas ﬁred Warm Air Heating)

8.1 RETURN AIR

8.1.1 A room-sealed heater can be installed without positive return air ducting, provided that the path between

the return air grille and the heater return air inlet is protected in such a manner that the required airﬂow is

maintained at all times (BS5864).

8.1.2 The return air grille MUST have a free area of not less than 900 cm² (140 in²). It is recommended that the

return air duct not be routed directly from the main living area, but from a convenient central area serving

the remainder of the dwelling.

8.1.3 The return air system should be constructed of ﬁre-resistant material where used. It is extremely important

that the correct size of return air grilles and ducting is used. The return air duct area should not be less than

450 cm² (70 in²). If ﬂexible duct is used the duct diameter should not be less than 300 mm (12”) diameter.

8.1.4 An adequate and unobstructed return air path is essential from areas not served by a directly ducted return

and to which warm air is delivered. All such rooms should be ﬁtted with relief grilles which have a free area of

0.0088 m2/kW (1 in²/250 Btu/h) of heat supplied to the room. The only exceptions are kitchens, bathrooms

and WCs.

8.1.5 The return air duct should allow for ease of removal for access to the ﬂue.

8.1.6 All duct work in the room or internal space in which the heater is installed shall be mechanically secured and

sealed with ducting tape.

8.1.7 If a return air duct is not to be ﬁtted, the top of the unit must be suitably guarded to prevent blockage.

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9. HEATING SYSTEM

9.1 WARM DELIVERED AIR SYSTEM

9.1.1 All duct work, including riser ducts, should be fully insulated with 50 mm (2”) ﬁbre-glass or

similar. If short extended duct runs are taken below ﬂoor level, these should be similarly

insulated and, in addition, wrapped with a sound vapour proof barrier. They must also be

protected from crushing.

9.1.2 The duct system should be carefully designed (as given in the guidelines in the British

System Design Manual) to suit the needs of speciﬁc heating requirements and building

layout. The type of duct system (e.g. radial/extended, plenum/stepped) should be

installed using the least number of ﬁttings to minimise airﬂow resistance. The base duct,

which equalises the air pressure to supply ducts, must be constructed to support the

weight of the heater, which must be sealed using self-adhesive foam strip, ducting tape

or sealing compound. All ducting and blanking plates must be mechanically secured and

sealed.

9.2 ADDITIONAL RADIATOR SYSTEM IF FITTED

9.2.1 Any additional radiators must be connected to pipe tails provided as detailed in Figure 3.

9.2.2 The installation must comply with all relevant national and local regulations.

All components of the system must be suitable for a working pressure of 3 bar and

temperature of 110 °C. Extra care should be taken in making all connections so that the

risk of leakage is minimised.

NOTE: a. The method of ﬁlling, reﬁlling, topping up or ﬂushing sealed primary hot water circuits

from the mains via a temporary hose connection is only allowed if acceptable to the local

water authority.

b. Antifreeze ﬂuid, corrosion and scale inhibitor ﬂuids suitable for use with boilers having

stainless steel heat exchangers may be used in the central heating system.

FIGURE 3. WATER FLOW SCHEMATIC

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9.3 PIPEWORK SIZING

In order to keep the noise of the system to a minimum, the velocity of water should be kept below

1.5 m/s and it should be noted that the appliance is designed to operate with a temperature

differential of 20 ˚C between ﬂow and return. The maximum ﬂow rates are 0.3 kg/s, which,

through a 22 mm pipe, give velocities of 1.00 m/s. Therefore, the recommended minimum pipe

size is 22 mm.

9.4 WATER TREATMENT

It is important that the system is ﬂushed thoroughly before the appliance is left to operate (as

recommended in BS 7593) in order to maintain an efﬁciently operating heating system and

in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating

Systems.

9.4.1 For replacement installations, the system MUST be ﬂushed with the old boiler in situ, in

order to prevent the boiler becoming a trap for system debris. Once the system has

been ﬂushed, an inhibitor (suitable for stainless steel heat exchangers) should be added.

9.4.2 Appropriate inhibitors are available, for example Sentinel, Fernox and Salamader. Failure

to carry out the above procedure will invalidate the guarantee!

NOTE: Water supplied from a water softener MUST NOT be used unless a specially

formulated corrosion inhibitor is added (see BS 6798).

IMPORTANT: This appliance can only be used with a Indirect heating System.

9.5 HOT WATER SYSTEM FOR DHW

9.5.1 A cylinder with a thermostat must be ﬁtted.

9.5.2 Separate timing of DHW is required for connections: see Figure 52.

FIGURE 4. HOT WATER SYSTEM SCHEMATIC

COLD WATER

STORAGE

EXPANSION

VESSEL

HOT WATER

DRAIN COCK

INDIRECT STORAGE

CYLINDER

NOTE: Johnson & Starley Ltd recommends the use of a

sealed system kit. The pressure vessel and PVR must be

ﬁtted in the ﬂow before any auxiliary diverter valves.

Sales/Spares & Replacement Help Line 01604 762881

10. FLUE INSTRUCTIONS

10.1 The WarmCair C10DW Condensing Air Heater is certiﬁed as a warm air heater with corresponding

ﬂue systems according to EU Directive 2009/142/EC on gas-ﬁred devices. These installation

instructions are covered by this certiﬁcation and are referred to in the design approval test

certiﬁcate.

10.2 The installation of the warm air heater and ﬂue system must be in accordance with the Gas Safety

(Installation and Use) Regulations 1998 and the Building Regulations. If no speciﬁc instructions are

given, reference should be made to the relevant codes of practice.

THESE RELEVANT STANDARDS SHOULD BE FOLLOWED

BS 5440:1 Flues and ventilation for gas appliances of rated heating input not

exceeding 70 kW (net) : Flues

BS 5440:2 Flues and ventilation for gas appliances of rated heating input not

exceeding 70 kW (net) : Air Supply

Ensure all legislation, regulations and directives mentioned are observed.

10.3 The air/ﬂue duct operates at very low temperatures therefore no clearance is necessary between

the air duct and the adjacent services.

10.4 Ensure while installation work is being carried out that no debris such as swarf, ﬁlings or fragments

of mortar are allowed to remain in the air/ﬂue duct.

10.5 TYPE OF FLUE SYSTEMS

Two types of ﬂue systems are available for the

C10DW.

i) The standard concentric ﬂue system 60/100

(100 mm diameter)

FIGURE 6. 60/100 mm FLEXIBLE FLUE EXAMPLEFIGURE 5. 60/100 mm HORIZONTAL CONCENTRIC FLUE EXAMPLE

VERTICAL TERMINAL

ii) A Flexible ﬂue kit (FFK 5) 60/100 mm (100

mm diameter). For further information

contact the sale ofﬁce at Johnson &

Starley Ltd. Telephone 01604 762881.

10.6 FLUE TERMINAL POSITIONS

10.6.1 The following information provides the general requirements for siting ﬂue terminals. As

part of the recommendation given in BS 5440 Part 1. For Ireland recommendations,

see the current issue of I.S. 813 “Domestic Gas Installations.” Also publication a “Guide

for Gas Installations in Timber Framed Housing DM2” or consult your local gas region, it

MUST be consulted when installing the appliance into a timber-framed building.

NOTE: Due to the nature of the warm air heater, water vapour will discharge from the ﬂue. This

should be taken into account when siting the ﬂue

10.6.2 Both the horizontal and vertical terminals must be positioned on the outside of the

building and the free passage of air must be available at all times. It is not recommended

to position the terminal close to projections especially under a balcony or near to a

drainpipe.

10.6.3 Ensure that combustion products cannot enter the building where the heater is installed

or near to any other building where doors or windows may be open.

10.6.4 Recommended terminal positions for both horizontal and vertical ﬂues are shown and

ﬂue components and installation options are also detailed.

10.6.5 The ﬂue MUST NOT be installed under a car port.

FLEXIBLE

FLUE

VERTICAL

ADAPTOR

FLUE

SUPPORT

90˚ ELBOW

45˚ ELBOW 1 m EXTENSION

1 m

EXTENSIONS

HORIZONTAL

TERMINAL

WEATHER COLLAR

VERTICAL TERMINAL

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FIGURE 7. TERMINAL POSITIONS

D, E

TABLE 3 TERMINAL POSITION MINIMUM DISTANCE

A Directly below an opening, air brick, opening window etc. 300 mm

B Above an opening, air brick, opening window, etc. 300 mm

C Horizontally to an opening, air brick, opening window etc. 300 mm

D Below gutters, soil pipes or drain pipes. 75 mm

E Below eaves. 200 mm

F Below balconies. 200 mm

G From a vertical drain pipe or soil pipe. 150 mm

H From an internal or external corner. Greater than 450 mm protrusion. 300 mm

I Above ground, roof or balcony level. 300 mm

J From a surface facing the terminal. 600 mm

K From a terminal facing the terminal. 1,200 mm

M Vertically from a terminal on the same wall. 1,500 mm

N Horizontally from a terminal on the same wall. 300 mm

Q Above intersection with roof. 530 mm

P From a vertical structure on the roof 300 mm

R From the terminal to the boundary 300 mm

Sales/Spares & Replacement Help Line 01604 762881

10.8 EXTENDED HORIZONTAL FLUE

CONFIGURATION EXAMPLE

NOTE: Vertical Appliance adaptor is ﬁtted

as part of the air heater.

Can be ﬁtted to the left or the right.

FIGURE 8. EXTENDED FLUE CONFIGURATION

100 mm

19 mm

CORRECT

POSITION OF

HORIZONTAL

TERMINAL END

10.7 FLUE REQUIREMENTS & GENERAL INFORMATION

10.7.1 Horizontal and vertical concentric ﬂues (60/100 mm diameter) with balanced terminals may be

installed on all the WarmCair C10DW appliance.

10.7.2 If an extended horizontal ﬂue is being used it must have a continuous fall back towards the appliance

of 3° (52 mm) per meter. This ensures that condensate runs back into the appliance from the ﬂue

system for safe discharge via the condensate waste pipe. Reference should be made to Table 5 for

relevant part numbers.

10.7.3 The maximum length of ﬂue permissible is 10 meters excluding terminal.

10.7.4 The minimum vertical ﬂue length is 1.25 m from the top of the appliance case to the top of the terminal.

10.7.5 Elbows may be ﬁtted within the ﬂue system with a corresponding reduction in overall ﬂue length.

10.7.6 Guidelines for the maximum ﬂue lengths are as follows.

EQUIVALENT HORIZONTAL FLUE LENGTHS

Adaptor + 10 metres straight

Adaptor + 1 x 90° Elbow + 8 metres straight lengths

Adaptor + 2 x 90° Elbow + 6 metres straight lengths

Adaptor + 3 x 90° Elbow + 4 metres straight lengths

When using 90˚ Elbows = 1 x 90° Elbow is equivalent to 2 m Straight lengths

When using 45˚ Elbows = 2 x 45˚ Elbows are equivalent to 1 x 90˚ Elbow

Flue Extensions

as Required

60/100 mm

Adaptor

Clamps

90° Elbow

ITEM DESCRIPTION QTY

1 Vertical 60/100 mm Adaptor 1

2 Appliance Seal 1

3 EPDM Outside Wall Cover Plate 1

4 Inside Wall Cover Plate 1

5 100 mm Diameter Clamps -

6 Required Extension Flue Length up to

8 m

7 90° Elbow 1

8 800 mm Horizontal Terminal 1

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FIGURE 9. VERTICAL FLUE

10.11 PLUME TERMINAL OUTLETS

10.11.1 A ﬂue duct outlet of an appliance should be at least 600 mm from the boundary line when facing

it and at least 300 mm from the boundary line when running parallel to it (See Figure 6).

NOTE: When the ﬂow of products is at an angle to the boundary, the 600 mm dimension may be

measured in the direction of the ﬂow, as long as the terminal is not less than 300 mm from the

boundary.

10.11.2 It is recommended the terminals are not sited within 2 m of an opening in an adjacent building

or within 2 m of the boundary facing the terminal if the plume is likely to cause a nuisance to a

neighbour, e.g. discharging over a walkway or patio.

ITEM DESCRIPTION QTY

1 Vertical 60/100 mm Adaptor 1

2 Vertical Terminal 1

3 1 m Extensions for required length 1

FIGURE 10. PLUME TERMINAL OUTLET DIMENSIONS

10.9 VERTICAL FLUE CONFIGURATION

EXAMPLE

NOTE: Vertical Appliance adaptor is

ﬁtted as part of the air heater. Can be

ﬁtted to the left or the right.

10.10 OPTIONAL ROOF OUTLETS

FLAT ROOF PITCHED ROOF

PITCHED ROOF PITCHED ROOF SIDE VIEW

500 mm

Pitched

Roof

Weather

Collar

500 mm

Flat Roof

Weather

Collar

20˚ to 50˚

Ridge

Terminal

Ridge

Terminal

Clamps

Flue

Extensions

Vertical

Appliance

Adaptor

Adjustable

length

60/100 mm

Adaptor

Clamps

1140 mm

Vertical

Terminal

1 m Extension

Sales/Spares & Replacement Help Line 01604 762881

TABLE 5. DESCRIPTION COLOUR QTY APPLICATION PART No.

60/100 Standard Horizontal Flue Kit White 1 Horizontal 1000-0020070

Turret White 1 Horizontal 1000-0020020

800mm Horizontal Terminal White 1 Horizontal 1000-0019830

Vertical Appliance Adaptor White 1 Vertical 1000-0024940

90° Elbow White 1 Horizontal & Vertical 1000-0018980

250mm Straight Extension White 1 Horizontal & Vertical 1000-0018960

500mm Straight Extension White 1 Horizontal & Vertical 1000-0018950

1000mm Straight Extension White 1 Horizontal & Vertical 1000-0018940

2000mm Straight Extension White w Horizontal & Vertical 1000-00025570

Flat Roof Weather Collar 1 Vertical 1000-0014900

Pitched Roof Collar Black 1 Vertical 1000-0014890

Ridge Terminal Grey/

Brown 1 Vertical 1000-0021030

Wall Fixing Bracket 100mm 1 Horizontal & Vertical 1000-0014970

1140mm Vertical Terminal

White/Black

1 Vertical 1000-0018930

Plume Management Kit Black 1 Horizontal & Vertical 1000-0020730

Flexible Flue Kit 60/100mm Black 1 Flexible FFK5

Chimney Terminal Kit 60/100mm Black 1 Vertical 1000-0026250

Skyline Terminal & Outer Flue Cowl Black 1 Vertical 1000-0023990

Locking Ring Grey 1 Vertical 1000-0026610

Flashing Ring Grey 1 Vertical 1000-0026660

Chimney Cover Plate 1 Vertical 1000-0026600

10.12 CONVENTIONAL 60/100 mm FLUE ACCESSORIES PARTS No.s

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FIGURE 12. CONDENSATE ROUTING OPTIONS

11. CONDENSATE PUMP & DRAIN TUBE

11.1 CONDENSATE PUMP

11.1.1 Supplied with 6 mm x 10 m condense tube. Condense adaptor and 2 x

clips.

SAFETY NOTE: If the pump fails, the safety ﬂoat switch will shut off the heater

operation.

11.1.2 DO NOT HANDLE PUMP IN WET CONDITIONS OR WITH WET

HANDS

11.1.3 TECHNICAL DATA

a) Tank capacity : 0.5 L

b) High level safety cut out

c) Outlet size 6 mm I.D.

d) Maximum water temperature: 60 °C

e) Maximum noise level: 21 dB(A) at 1 m

11.1.4 Where the tubing from the pump is connected directly to the soil stack

or waste pipe, there must always be either a waste trap after the tubing

connections, or a 75 mm U trap formed within the tubing.

11.1.5 Where the tubing from the pump is connected to an external soil and

vent stack extra care is necessary to ensure that the condense pipe

could not be blocked through the condense freezing.

11.1.6 The tank pump uses small bore (6 mm) ﬂexible hose which can be

routed above or below doors, windows and under kitchen cabinets.

IMPORTANT: Ensure the condensate tube is protected and

cannot freeze in an unheated area.

11.2 CONDENSE TUBE ROUTING OPTIONS

Option A. Routing to outside drain via sink

Option B. Routing to drain pipe via roof

Option C. Routing to bath waste

Option D. Routing to under ﬂoor

to sink waste

NOTE:

10 m MAXIMUM

HEAD LENGTH OF

CONDENSE TUBE

RESERVOIR

FLOAT FILTER

FIGURE 11. CONDENSE PUMP

Sales/Spares & Replacement Help Line 01604 762881

12. ELECTRICAL

12.1 The appliance is supplied with PVC sheathed, 3 core (Brown-Blue-Green/Yellow) 0.75 mm2 CSA

rated at 6 A, connected to a terminal block and exiting through the casing at the top left hand

front. The cable is suitable for a 230 V - 50 Hz single phase supply.

12.2 The means of isolating the appliance MUST be via a double pole switch with a contact separation

of at least 3 mm in both poles, and fused at 3 A. If switched live is ﬁtted, a triple pole switch should

be used.

12.3 An OpenTherm Controller is supplied with the unit, which is to be connected using PVC sheathed

to BS 6500, 2 core cable of 0.5 mm2 CSA rated at 3 A, to terminals 29 & 30 on the PCB in

accordance with Figure 52 and observing correct polarity.

13. WARM AIR FAN PERFORMANCE

14. OPERATING MODES

14.1 Operating modes are covered in the User Instructions, ZZ1449 packed with the appliance, for

both Domestic Hot Water and Central Heating.

14.2 For heating systems that include additional heating circuits e.g. radiators, circuit instructions for

use and installation will be provided within additional control packages provided.

14.3 For installations that include a solar water circuit to the domestic hot water cylinder, instructions

for use and installation will be provided within the solar heating kit.

FIGURE 13. FAN PERFORMANCE GRAPH

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15. DOMESTIC HOT WATER HEATING COMMISSIONING

15.1 CHECK GAS INSTALLATION

15.1.1 The whole of the gas installation, including the meter, should be inspected and tested for

tightness and purged in accordance with the recommendations of BS 6891. In Ireland

refer to IS 813.

15.1.2 Purge air from the gas installation by the approved methods only.

NOTE: The combustion for this appliance has been checked, adjusted and preset

at the factory for operation on the gas type deﬁned on the appliance data plate. No

measurement of the combustion is necessary. Do not adjust the air/gas ratio valve.

15.1.3 Having checked the heater has been installed in accordance with these instructions. The

integrity of the ﬂue system and the ﬂue seals, as described in the Flue Installation section.

Proceed to put the boiler into operation as follows:

15.2 CHECK THE OPERATIONAL GAS INLET PRESSURE

15.2.1 Set up the heater to operate at maximum rate by opening hot tap to

maximum ﬂow.

15.2.2 With the heat generator operating in the maximum rate condition,

check the operational gas

pressure at the inlet gas pressure test

point complies with the requirements. See Figure 13.

15.2.3 Ensure that this inlet pressure can be obtained with all other gas

appliances in the property working.

15.3 AIR PURGE FUNCTION

15.3.1 On initial power up an air purge cycle is initiated.

15.3.2 Ensure air bleed valve is open.

15.3.3 Ensure air bleed valve is open on initial power up and air purge cycle

is indicated.

15.3.4 During this function, heat demand is switched off and combustion

fan will run at maximum for 120 seconds.

15.3.5 Also at the same time, the circulation pump will be switched on for 5

seconds and off for 5 seconds continuously.

15.3.6 Diverting 3 WV (three way valve) will be moved in CH position for the ﬁrst 30

seconds, then in DHW position for 30 seconds, then in CH position for 30

seconds and ﬁnally in DHW position for 30 seconds.

15.3.7 In this way, air is expelled from the circuit. On completion of this function

normal operation of the circulation pump will occur.

15.3.8 During the fan on period, there will be an indication on the LCD display:

15.3.9 Function can be skipped pressing K4 push button twice.

This function can be activated by four conditions:

a. If the controller is plugged in to the Mains for the ﬁrst time.

b. After a manual reset to reset the lockout fault E03: High limit temperature protection.

c. When the central heating water pressure is built up to the normal level after the fault

F37 or fault F40.

15.3.10 If there is no heat demand afterwards, the controller will switch to standby mode.

FIGURE 15.

AIR PURGE LED

READ OUT

FIGURE 16. LED DISPLAY FUNCTIONS

K7 K1

K6 K2

K3 K5

ITEM DESCRIPTION

K1 + Installer function only

K2 - Installer function only

K3 Installer information

K4 Reset

K5 Summer/Winter mode

K6 No Function

K7 No Function

15.5 RESET PROCEDURE - To reset boiler press the reset button “K4” twice.

FIGURE 14.

GAS PRESSURE TEST POINT

Sales/Spares & Replacement Help Line 01604 762881

16. INITIAL LIGHTING

16.1.1 Check that the system has been ﬁlled and the heat exchangers are not air-locked.

NOTE: It is important the burner is not operated before the system is fully vented of air.

IMPORTANT: The gas input to the burner is regulated by the gas valve according

to the air ﬂow produced by the fan. It is not user-adjustable. Any interference to

sealed settings on the gas valve will adversely affect operation and render our

warranty void.

16.1.2 Reﬁt the boiler front panel. See Paragraph 17.5.

16.1.3 Check that the electrical supply is OFF.

16.1.4 Check that the gas service cock is OPEN.

16.1.5 Slacken the screw in the inlet pressure test point and connect a gas pressure gauge via

a ﬂexible tube.

16.1.6 Switch the electricity supply ON and check all external controls are OFF. The heat

generator will select “self purge”.

16.2 WARM AIR CENTRAL HEATING

16.2.1 Set the CH temperature to maximum and switch on external control. The heat generator

control should now go through its ignition sequence until the burner is established.

16.2.2 If the heat generator does not light, code E-01 will be displayed.

16.2.3 Reset the heat generator (see Paragraph 15.5). The heat generator will repeat its ignition

sequence. If reset occurs 5 times within 15 minutes, F-15 will be shown. If power is

removed, this will be reset.

16.2.4 When the burner is established the display will show the “ﬂame symbol”.

16.2.5 Ensure that the CH external controls are calling for heat. The burner should

light.

16.2.6 Gas Rate: Check the heat generator gas rate when the heat generator is

at full CH output.

Check at the gas meter, with no other appliance in use. Refer to Table 2 for

gas rates.

16.2.7 Set the central heating external controls to OFF. The burner should go off and the pump

continue to run for two minutes.

16.2.8 Check the correct operation of the timer (if ﬁtted) and all other system controls. Operate

each control separately and check that the main burner responds.

16.3 WATER CIRCULATION SYSTEM

16.3.1 With the system still hot, turn off the gas, water and electricity supplies to the boiler and

drain down to complete the ﬂushing process.

NOTE: A ﬂushing solution should be used during the ﬂushing procedure. Flushing solutions:

Fernox Superﬂoc, Sentinel X300 (new systems) or X400 (existing systems). Refer to

Paragraph 8.8.

16.3.2 Reﬁll and vent the system, add inhibitor, clear all air locks and again check for water

tightness.

16.3.3 Reset the system initial pressure to the design requirement.

16.4 BALANCE THE SYSTEM (if radiator system is ﬁtted)

16.4.1 The heat generator does not normally need a bypass but at least some radiators on the

heating circuit, of load of at least 10% of the minimum heat generator output, must be

provided with twin lockshield valves so that this minimum heating load is always available.

See note regarding thermostatic radiator valves.

NOTE: Systems incorporating zone valves which could completely cut off the ﬂow through the

system must also include a bypass.

16.4.2 Check the condensate drain for leaks and check that it is discharging correctly.

16.4.3 Finally, set the controls to the User’s requirements.

NOTE: The circulation pump will operate brieﬂy as a self-check once every 24 hours in the

absence of any system demand.

16.5 CENTRAL HEATING WATER TEMPERATURES

Temperatures can be selected using the CH

thermostat See Table 5.

16.5.1 Set water differential to 20 °C using

lockshield valve or equivalent.

16.5.2 Check fan stops when water cools to

minimum temperature.

TABLE 5.

Button Setting CH Flow Temperature °C

Max 80

Min

FIGURE 17.

LED READ OUT

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17. WARM AIR HEATING COMMISSIONING

17.1 Ensure the heater is correctly ﬁlled with water and all air vented from the ﬂow and return circuits.

17.2 Switch on electrical supply.

17.3 Setting maximum speed.

a. Remove the PCB cover plate.

b. Make a short across summer vent connections on the PCB interface and adjust the fan

speed as required using a small screwdriver on the warm air PCB to turn the relevant pot.

Remove the short.

17.4 Setting minimum fan speed.

a. Make a short across the pipe sensor or minimum fan adjustment of PCB interface and

adjusted the fan speed as required, using a small screwdriver on the warm air PCB to

turn the relevant pot. Remove short.

17.5 WITH OPENTHERM CONTROLLER FITTED

17.5.1 Turn up OpenTherm Controller to call for heat.

17.5.2 With the water at the required temperature, ensure fan starts (when the display shows

62 °C to 68 °C).

17.5.3 Allow the system to warm up and check temperature rise across unit is 40 °C.

17.5.4 Set water differential to 20 °C using lockshield valve or equivalent.

17.5.5 Turn off OpenTherm Controller and check there is NO 230 V on switch live out.

17.5.6 Check fan stops when water cools to minimum temperature.

17.6 WITH NO OPENTHERM CONTROLLER FITTED

17.6.1 With the water at the required temperature, ensure fan starts (the display shows 62 °C

to 68 °C).

12.6.2 Allow the system to warm up and check temperature rise across unit is 40 °C.

18. HANDING OVER

18.1 Hand the User Instructions to the householder and explain his/her responsibilities under the

relevant national regulations.

18.2. Explain and demonstrate the lighting and shutting down procedures.

18.3 The operation of the heater and the use and adjustment of all system controls should be fully

explained to the householder, to ensure the greatest possible fuel economy consistent with the

household requirements of both heating and hot water consumption. Advise the User of the

precautions necessary to prevent damage to the system and to the building, in the event of the

system remaining inoperative during frosty conditions.

18.4 Explain the function and the use of the boiler heating.

18.5 Explain the function of the heater Fault Mode. Emphasise that if a fault is indicated refer to “Fault

Codes” in the User Guide.

18.6 Explain and demonstrate the function of time and temperature controls, radiator valves etc., for

the economic use of the system.

18.7 If a timer is ﬁtted, draw attention to the Users.

18.8 Explain heater reset procedure.

18.9 After installation and commissioning, please complete the Commissioning Checklist before

handover to the customer. For Ireland, its is necessary to complete a “Declaration of Conformity”

to indicate compliance to IS 813.

IMPORTANT:

18.10 A comprehensive service should be carried out ANNUALLY. Stress the importance of regular

servicing by a Gas Safe Registered Engineer. In Ireland, servicing work must be carried out by a

Registered Gas Installer (RGII).

18.11 Inform the householder of the guarantee/registration found within the folder pack and the

requirement to register it to receive the full beneﬁt of the

warranty.

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Johnson & Starley WARMCAIR C10DW Installation guide

Brand: Johnson & Starley

Model: WARMCAIR C10DW

Category: Water heaters & boilers

Type: Installation guide

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Johnson & Starley WARMCAIR C10DW Installation guide

Johnson & Starley WARMCAIR C10DW Installation guide

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